Soldering tips

[montmil]

One of several "money pits" that I own (including the 1981 R65 I've recently purchased) is a 1986 Volkswagen cabriolet. I've always wanted one and have been the caretaker of this particular issue for over ten years. It's my daily driver with over 225K miles. I usually do all the maintenance on the car and belong to a web-based group that, like this one, helps me keep the cabby going. This also saves me a chunk of change.

Wiring issues in older cars and motorcycles can be easily overlooked while you continue to toss large amounts of money chasing phantom problems. Many of these problems are caused by 'vintage' wiring- breaks within the sheathing, corroded or rusty terminals, poor soldering, etc. How well I know. The lesson was expensive.

Tip numero uno:  GROUND WIRES. I cannot remember how many problems I have cured on the cabriolet by simply replacing old ground wires; usually brown colored in German products. Check your shop manual to be sure of the color/s.

My greatest improvement, according to the volt gauge, occurred when I fabricated new battery leads. The original battery ground cable was a braided copper strip, unshielded, and about two feet long. Old and nasty. I replaced both battery leads with #2 sheathed copper cable and had the local NAPA shop swage on solid copper ring terminals. Wow!

Tip numero dos:  AVOID ganging replacement grounding wires onto each other. This will most definitely bite you later.

Tip numero tres:  To INCREASE THE OUTPUT OF YOUR HEADLIGHT, consider installing a simple and inexpensive relay. All original switches maintain their function but will now only serve to turn the relay on/off. Ever notice your car's headlight switch getting hot? Lots of amperage going through small wires and increasing the voltage drop before the power gets to your bulb. This suggestion can save you from spending big bucks on high dollar driving lamps and still not seeing a lighting improvement.

Here's a link that offers help for the soldering challenged among us:

http://en.wikipedia.org/wiki/Soldering

Another link to a wee small business - as in one guy named Mark - that offers automotive electrical supplies such as wire, pre-tinned terminals, fusible links and lots of tech info. I'm a customer.

http://madelectrical.com/

OK, enough for this posting.  Soldering is an easy skill to learn and pays big dividends. Supplies are inexpensive and practice materials are bound to be in your shop. Just don't use acid core solder for electrical work! Bad solder. No biscuit.

[nhmaf]

Corrosion/heavy oxidation on the surface of copper wires has a very significant effect on the wire's resistance.  Since en electric field cannot be maintained inside of
a conductor, all of the electron migration and electromotive force to sustain current flow occurs on the surface/skin of the conductor.  IF the surface is corroded, etc. then the
current must flow between, around and under non-conductive oxidation/corrosion deposits, and thus meets higher resistance as the entire circumference of the cable is not conductive.   For the initial starting surge current needed by the starter motor a fraction of an ohm greater resistance in the battery cables can cause one to lose as much as a couple volts at the starter, resulting in slower starter speed.   Don't forget that the starter contacts need to be looked at/cleaned/maintained once in a while, too !

[montmil]

Yeah, just like I kinda said. Only more testicle    We could probably use some additional electrical and wiring postings within the FAQs area.

I actually had a college art prof whom had lost electrical power in a portion of his home. Guy had just moved everything into the powered up parts of the house. During a class break, couple of us talked him into taking us to his house. Duh. Green Acres-type guy had too much load on too few circuits. Couple old-style fuses and a quick electricity lesson got his power back. Too funny. I got an "A" for the semester... I actually got it the old fashioned way... I earned it.